Method of forming brickkilns



Aug. 26, 1930. A. J. THERRIEN l METHOD 0F FORMING BRICKKILNS originai .Filed nay 2s, 1928 75- f6 77 ya Patented lvAu'g. r26, 1930 a 'UN-flTEYDsTAT-Es "PATENT OFI-Ici:

,ARIII'UNI THERRIEN, oF NoIvIIIBRooK, IIiLINoIs, AssIGNoR To NATIONAL BRICK A `COlVIPANY,l OF'CHICAGO, ILLINOIS,` A CORPORATION OIEv ILLINOIS .METHOD OF FORMING BRICKKILNS Appnatimraied my 2s,f1928,`seria1`No;281,018. Renewed July 7f19'ao."

,i The present invention relates to the manufacture of brick, and While the invention herein described Vin detail relates to the manufacture of common building bricks, the inven- 5 tion is not limited to anyiparticulargrade of e brick. Y

The present application discloses a continnation of some of the subject matter disclosed .in my prior application, Serial No. 83,342,

7,10 filed January 23rd, 1926, andalso certain improvements over the methods described there- 1n dryer. 7

When the piles havek f passed lthrough, thek dryerand been consolidatedand taken up by the fork, theyare then placed in position in the kiln, and thevkiln is built up with arches of green brick `ofasingle brick-length .inv

Width extending from'side to side of the kiln. The' kiln is scoved in any preferred'manner,

. as for example, by's'mearing over thesurface valong the sides and 'ends' a mixture offgbrick ,25` dust and Water, or brick dust clay and Water,

burners arer inserted at each end .of each arch outsidesurface `ofthepkiln.,` Obviously, ret l movable scoving having suitable restricted openings for communicatmg with ytheends ,of the arches may lb'eg'employed ifdesired.

'Y Firing iscarried on from each end ofther arches, andthe objectof the firing is, :of

course, to'burn the bricks, and -this is accom- Y VVthe transfer or dryer car.

plished most yeffectively by filling the arches f4.0 from end' to end With fire fromf the burners. Due to the relatively large rat-io of escape n,

' openings bet- Weenbricks to thevolume definedv by the arch, the burning'is much more rapid v and satisfactory and results in less slaggi'ng or melting of the bricks in the "arches than has been thought possible prior to my invenition.- 'w n j y- While preferably open: clamp kilns are ernplovcd thismethodfof burning brick, and

I shall describea speciic embodiment em- The bricks are hacked onto drying cars, in t piles, and then placed in a suitable. oven or ploying the same, there are certain features loit my invention Which may be employed in the manufacture of brick regardless of the kindV of kiln employed.

process, I shall describe in connectiony with the accompanying drawing atypical layout vv'of the kiln. 'y Y n y 'Fig l isa top, plan vieivof a kiln With certain of the layers removed to show the theburners in position. f

Ying up the arches betvveenfunit piles, as is performed inthe center of thekiln shown inFig. 1f

making up the-kiln; andy i y l Fig. L tisa planvieW-of a modified or alternativemethod of making up the arches from` solid unit'pil'es of brick.

I Accordingto a Well known method of mak- `ing'the green` brick, the clay is` taken' from* [the pit, tempered, pugged and'squirted through a die of single or multiple form 'onto a `cutting table Where the `longitudinally .ex-

truding,` stream vof A clay is cutl into brick from the brick machine,soth at ,the bricks will beseparated from each other ashort rspacel f, as they come to themen who take thebri'cks 'from the Ahacking table'V and pile them and the Workmenpilethe brick onto the car in asuitable manner. toV form` 2 pilehaving an arch extending therethroughl i After the car hasbeen iilled it is thenpassed ,ong ,andV pushed into the v,dryers AWhere 4the Now in order to acquaint those skilled in f the art Wit-hqthe manner `of practicing my# manner of building the same, and showing Fig. 2 is atop plan viewlof a` fragmentary part of thekiln,shovving. tlieinanner' of clos- 1Th'e-car is run alongsidethe-liacking table' p Fig. 3 isa-section through a partogt kiln j i illustrating diagrammaticallythe-'manner of 5' d0' lengths.l yFrom thence kthe green bricks go onto a hacking table, Which is generally a belt e traveling at a rateotspeed vgreater than the, l 1 `rate of speedat which the clay is extruded upon Y Y so bricksgare'subjected tohotV gases for-drying. c

After the car passes through the dryervthe pile of brick is removedther'efrom by a suitable fork and transferred to the kiln,

l vThefork is carried by the crane mounted in an overhead position, as indicated in dotted lines in Fig. l at G9, the fork being suitably connected to the car which is adapted to more longitudinally of the crane G9 and transverselytothelengthofthekiln. r he overhead crane 69 travels on the overhead longitudinal tracks 71, 72 mounted on top of the posts 73 and T4 placed at the sides ot the kiln. These posts also preterably support a suitable root. The crane 69 traveling on 'the tracks 7l and 7 2 longitudinally has the crane ear and hoisting mechanism 7() connected to the tork so that the fork may be brought` to any position 'within the kiln space. and may be turned into any angular position desired.

In piling the brick into the kiln the unit piles with transverse arches in them are set upon the kiln iloor, a s shown in Fig. l. `First a unit pile such as 75 at one corner of the kiln with the longitlnflinal axis of the pile extending longitudinally ot the kiln floor and with the arches 30 and 3l, which are formed therein, disposed. transversely ot the kiln floor. Thereupon a sei-ies ot unit piles such as 76, 77 and 78 are set upon the floor in contact with each other and all with their `arches in alinenient. Likewise upon the opposite side ot the kiln 'floor and beginning at one corner there willbe placed a similar series of unit piles beginning at the outer end and set inwardly towards the center. The reason for setting in this manner is because the track 7l. 72 for the crane G9 does not permit the crane car 70 and hence the fork to be carried beyond. the line of the track on either side, and hence to till the entire kiln floor as tull as possible it isnecessary to start piling at the outer edge and pile inwardly. In the instance shown in l? l there are four unit pil-s 75, 7G, 77 and 78 on the left hand side. and likewise there are four unit piles on the right hand side, leaving a space between them substantiallyY en brick-lengths wide.

This space is necessary to permit withdrawal ot the tori( troni the innermost unit pile after it is set. This (waiter space is then filled with solid unit piles, that is. unit piles having no arches formed therein when the vbric (s are hacked onto the car. For torining the unit piles placed in this center space, suitable cars are cniplrwedand solid unit piles are hacked onto the ears, dried` compacted, lifted with the fork and deposited in the center. The outermost pile in the center part ot the lowermost layer ot the kiln indicated at 8O is of only two brick-lengths in thiekziess, and this halt unit pile S() is set with its innermost edge .in line with the adjacent edge ot the arch 30 and with its outermost edge in line with the edges of the Vtunnelled piles 7 5, 7 6, 77 and 78, and like tunnelled piles on the ri ght hand side as viewed i in Fig. l.

The next unit pile 8l. which is put in the center space between the tunnelled piles, is et 'tour brick-lengths in horizontal thickness, and so likewise are the remainder ot the piles 82, 83, etc.

After the central piles such as 80, '81, 82 etc. are set into place, workmen with eXtra dried bricks turn the arches by the following operation, as illustrated in Fig. 2, that is to say, a layer ot brick on edge is pro ected out trinisversely oyerhanging the space 84 between the two piles 80 ane 8l, this space between the piles 84 being in alinei'nent with the arch 30.

Likewise troni the pile ,Si a row ot bricks on edge is projected out 'transversely over the space 8l. These bricks such as ii'ldicated at S5 and 85 on opposite sides oit the space Sel, extend ontiynixily an anionnt substantially equal 'to the thickness ot a brick, and then a row ot brick as indicated at Sti arranged end to end is laid back. ot the bricks 8d. A siinila r row ol bricks S7 end to end is back ot the bricks S6 to lill in the space which is lett by the advance oit the bricks 86 out over the edge ot the pile.

ln the lower right hand corner ol" Fi 2 the operation et jetting these bricks out in order to turn the arches is shown in process. That is to say7 the bricks 88 and 89 are shown as pulled ont tron; the position formerly occu* pied by them, and bricks 90l and @l as being' placed back of they bricks 88 and 89. in this inanner arches are termed as continuations ot the arches 30 and 3l in the unit piles 75, 7G, 77, and 78 and so on entirely through the bottom layer of' unit piles in the iln. ln this manner the entirerlower layer ot' the l'iln is completed with arches running transversely thereacross. It will benoticed that the space between piles such as 80, Si or Si, 82 and 'the like are not completely closed over in the lower layer, but that a space as shown in i'ligs. l and 1 Vin the topinost tier ot bricks oi the unitpiles 8l?, etc. Titien the 'i'iext layer ot unit pilesI is placed on top o i the lmw-rinosl; layer or tier ot piles, these unit piles above the lowern'iost layer or tier are all solid unit piles. The pickup bricks ot the solid piles span the space remaining between the piles such as 80, 8l, and the like, and complete the arch thereby.

The unit piles el 'the second layer or tici in the kiln areindicated at 93', and they n'iay be set in any desired position so long as they bridge over the arches between piles SO, 8l.. 82etc. Thereafter ade` itional layers or tiers of unit piles oi brick i, lhout arches, as indicated at 9e, are set in place ine-.ny desired or usual manner to bring' the kiln by successive layers or tiers to the desired height.

Thereafter the outside oi the'kiln is scored as, 'tor example, by piling a single layer et burned brick or brick stacks around the ontside ot' the kiln except in line with the arches, and daubing the saine with a suitable sealing i material which may be clay and brick dust. i

- fuel, for example, oil and steam or oil and air,

v Asa result the fire may be made'to penetrate arches is also 'of great importance. use a greater number of arches, that is,'in a `cording to 'my present inventionl AI employ Y about thirty arches, but because ofthe much be 'built out from the arches to receive the The outer layers of the kiln may have powdered coal incorporated therein to assist in ,making up the loss of heat due to radiation,

as is well known in the art. Dog houses may burners indicated atv95 and 96 at opposite ends of the arches so as to bring the flame from these burners in contact with the outermostlayers of the brickof the kiln. The burners 95 and 96 are supplied with suitable rlower layers hot, be subjected to full fire and the kiln then burned rapidly. y

Usually it takes a progressive heating along the arches to get the bottom layers hot, and it is to be observed that'with the single brick-length arches of my invention it is much easier to get the bricks hot with vprogressive burning fromtheoutside towardsthe center than has been the case heretofore where arches fare of awidthygreater than a brickflength.

the lower'layers of the kiln more rapidly than has heretofore been possible, and the saving in time of burning is ofgreat-importance. Whereas ithas taken about' hours heretofore to burn a kiln of brickset with arches of the usualv size, it is now possible with avkiln of my invention toreduce the burning time to about 48 hours. A* s y v p f p The saving in labor by having the narrow l.

Vhile I kiln ofapproximately onemillionvbricks, itl was customary previous to my invention to I vpovide substantially twentydive arches. i Ac'- smaller number of bricks to be setby hand, several workmenmay be dispensed with. It was previouslynecessary in setting the arches for the workmen to handle( about four thousand bricks to the arch, while by my invenvtion it is necessary to handle only aboutl one j hundred bricks "for each arch where 4the brick-length arch, I'inay employ only solid arches are 'constructed as. shown in Figs. 1 and2. 's ,s

As an alternative form of making the single piles as at thel center of the kiln shown in Figs. 1 and 2, and construct the arches by setv ting V,the piles all transverselyofthe'floor, as

indicated'in Fig.v the lowermostvcourse of the kiln,separating the solid piles such asl 100, 101 and 102 by spaces for arches, which spaces are indicatedat 103 and 104 in Figwi of a single brick-length in width.

L'Ivhen the turningof the arches by 'jetting out the bricks isthe saine as shown in Fig. 2. yThereafter the second layer is set as shown in F 3, and so on up through the rest ofthe kiln. In this alternative forinof setting the .v

lowermost layers itis Vnot necessary to pre- 'form the arches vin the unit piles.

` AlfVhile I have shown in Fig. 1 thetwo meth,-

ods of forming the arches in combinatiomit; `is to be understood that either method may f be practicedalone if desired, but in the'event that the preformed arches are employed throughout the lowermostlayer of the kiln, space must beprovided alongffoney sidevof 'l the kiln for withdrawing 1the fork.v This is 'possible in'many installations where thereis a loading shed alongside of the kiln floor and the crane is employed to span both the kiln Y fioor and the loading space.

I do-not intend to' be limited to the, details shown and described.

I claim: v 1. The process Aof building an openclamp kiln which comprises placinga series of unitf i piles af iinburned-bricks on the floor of the kiln with spaces substantially afbrick-length. in width between successive piles of the sef Y ries, then sliding the bricks at` the top ofthe piles outwardly so that they extend out partiallyacross the spaces, filling in the spaces 1 in tlievtop spaces of the piles made vacant by the. change of position of the extended brick, and then placinga second series ofl unit piles of-'unburned bricks on top 'of the rst namedseries's'o as to close the tops ofthe arches par` tially formed by the extending brick.

.the floor of a kiln a series of rows of unit piles 1 of unburned bricks wit-hspaces substantially Y brick-length in Width between successive rows, then changing the position of thebricks at'the tops of the piles along said rows so that such bricks extend out partially across Ithe spaces, then placing ontop of said piles and saidpartially closed arches a solid layer .of h

unit piles of green bricks servingy to complete 4the closurevof said arches. i 3. The processof building an openclamp.v

kiln which comprises placingtransversely of the floor of the kilna'series of rows yof'iinit'1 rpiles of unburned bricks with spaces between I successive rows, then changing the position of thebricks of theV top layer only along .said spacesslo that such bricks extend out over the spaces less than a half 'biick-length',.' filling in the spaces in the top spaces of the unit piles 2; The process `of building an open clampr kiln which comprises r'placing transversely of made'vacant by thechange of position ofthe Y outwardly extended bricks, andthen placing c on top gof sa'idvpiles andthe partially closed arches between the piles awsolid layer of unit piles, the successive spaces between the rows being olfv such a width that the superposed unit piles serve to cornplete the closure of said arches.

4. The process oi building,- an open clamp kiln which comprisesv placing; a serie-s of unit piles of unburned bricks on the loor of the kiln with spaces substantially a brick-length in width between successive piles of the series7 then changing the position of the bricks at the top of the piles so that such bricks eX- tend out partially across the spaces, and then placing` a second series of unit piies o't iinburneil bricks on top of the first named series so as to close the tops of the arches partially Vformed by the extending brick.

The process of building an open clainp kiln which comprises placing a series of unit piles of green brick on the lioor o'l the kiln with spaces substantially :i brick-length in width between successive piles of the series, then changing the. position of 'the top layer of bricks only at each side of each of the spaces so that they extend out partially across the spaces, then placing a row of bricks end to end back of the bricks so extended ontA and then placing a second series of unit piles of unburned bricks on top of the lirstnanied se ries so as to close the tops of the arches partially formed by the extending brick.

In witness whereof I hereunto set my hand this '124th day oi" May, 1928.

ARTHUR J. THERRIEN. 

